Modular building system utilizing composite, foam core panels

ABSTRACT

A system is for constructing a structure and includes composite panels having a laminate structure. The laminate structure includes a foam core to which are attached cover layers of the same or different material. One or both of the cover layers may include composite sub-layers. The system includes a number elongate and preferably extruded components for connecting the panels to form walls, roofs or floors for the structure. The system is modular, thereby providing a time and cost efficient approach for erecting a structure.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application claims priority from U.S. application Ser. No.61/310,991, filed Mar. 5, 2010, the entire contents of which areincorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to composite, foam core panels and tosystems for constructing buildings using such panels.

BACKGROUND OF THE INVENTION

There is a demand for modular building systems that allow a building tobe erected in a simple and time efficient manner. To address this need,various systems have been proposed that incorporate prefabricatedstructural members that are transported to a building site and assembledtogether to form a building. In some cases, the structural members arecompleted wall units that are generally large and difficult to transportand handle. It is also known to use structural insulated panels in theconstruction of walls, roofs etc. Such panels comprise a “sandwich”structure made of an insulative foam core positioned between two layersof plywood or oriented strand board (OSB) etc. Although such panelsprovide the desired insulation function (due to the foam core), the woodbased “skins” are subject to deterioration due to elemental exposure(i.e. water) or infestation by insects, microorganisms (e.g. mold).

In one alternative, building panels have been proposed that incorporatean insulative foam core, as with the panels described above, but,instead of a wood based skin, these panels include polymeric or metallicskins. In some cases, multiple layers of skins are provided to addressspecific requirements such as strength, water repellency etc. Someexamples of such composite building panels are provided in the followingreferences: US 2008/0127607; US 2004/0067352; U.S. Pat. No. 7,527,865;U.S. Pat. No. 6,481,172; U.S. Pat. No. 6,358,599; and U.S. Pat. No.6,093,481.

In addition to various composite panels, various systems to erectbuilding using such panels are also known. In general, such systemsinclude connecting members that serve to join adjacent panels together.One issue to address in such systems is to ensure a complete seal aroundthe enclosure to prevent water penetration and/or heat loss. Someexamples of known panel based building systems are provided in thefollowing references: U.S. Pat. No. 7,603,822; U.S. Pat. No. 6,418,681;U.S. Pat. No. 6,305,142; U.S. Pat. No. 6,279,287; U.S. Pat. No.5,921,046; and U.S. Pat. No. 5,373,678.

Although the above mentioned building systems have various efficiencies,there still exists a need for an improved composite panel and animproved building system incorporating same. For example, a buildingsystem that can be assembled quickly and efficiency would be desirable.

SUMMARY OF THE INVENTION

In one aspect, the present invention provides a system for constructinga structure comprising: a plurality of generally planar building panels,each of said wall panels having a laminate structure comprising a rigidfoam core slab sandwiched between first and second cover layers, thepanels comprising wall panels, roof panels or floor panels; and, aplurality of panel connecting components for connecting the panels toform walls, roofs, floors or combinations thereof; the connectingmembers including means for receiving ends of adjacent panels.

In one aspect, the present invention provides a system for constructinga structure comprising: a plurality of generally planar wall panels,each of the wall panels having a laminate structure comprising a rigidfoam core slab sandwiched between first and second cover layers; and, aplurality of corner joint, or connecting components including a pair ofangularly separated slots adapted to receive ends of the wall panelsforming a corner of the structure.

In another aspect, the invention provides a system further comprising: aplurality of generally planar roof panels, each of the roof panelshaving a laminate structure comprising a rigid foam core slab sandwichedbetween first and second cover layers; and, a plurality of roof joint,or connecting components including a first engagement means adapted toengage upper ends of the wall panels, when erected, and a secondengagement means adapted to engage ends of the roof panels.

In another aspect, the invention provides a system further comprising aplurality of floor panels, the floor panels having a laminate structurecomprising a rigid foam core slab sandwiched between first and secondcover layers.

In other aspects, the invention provides sill components for supportingwall panels and/or floor panels, ridge joint, or connecting components,for forming roof panel into a ridge of a roof, and seam connectingcomponents for connecting adjacent wall or roof panels.

BRIEF DESCRIPTION OF THE DRAWINGS

The features of the invention will become more apparent in the followingdetailed description in which reference is made to the appended drawingswherein:

FIG. 1 is cross sectional view of a panel according to one aspect of theinvention.

FIG. 1 a is a cross sectional view of a panel according to anotheraspect of the invention.

FIG. 2 is a schematic illustration of a panel manufacturing method andapparatus according to an aspect of the invention.

FIG. 3 is a top cross sectional view of a linear wall joint formed bytwo adjacent composite panels.

FIG. 4 is a top cross sectional view of a corner wall joint formed bytwo adjacent composite panels.

FIG. 5 is a cross sectional elevation view of joint formed between awall panel and a roof panel according to one aspect of the invention.

FIG. 6 is a cross sectional elevation view of a roof sectionillustrating the joints between wall panels and roof panels and betweenadjacent roof panels in a gabled roof format.

FIG. 7 is a cross sectional view taken along the line A-A of FIG. 6.

FIG. 8 is a cross sectional elevation view of a base section of a wallaccording to an aspect of the invention.

FIG. 9 is a cross sectional elevation view of a base section of a wallaccording to another aspect of the invention.

FIGS. 10 to 12 are cross sectional elevation views of a base section ofa wall according to aspects of the invention showing wall and floorpanels in combination.

FIG. 13 is a cross sectional elevation view illustrating a two compositefloor panels according to one aspect of the invention, supported on ajoist.

FIG. 14 is a schematic illustration showing the various components ofthe invention according to another embodiment.

FIG. 15 is a cross sectional elevation detail of a wall constructionaccording to an aspect of the invention showing the base portion of thewall.

FIG. 16 is a cross sectional elevation detail of a wall constructionaccording to an aspect of the invention showing the top portion of thewall.

FIG. 17 is top cross sectional view of a wall construction detailaccording to an aspect of the invention showing a corner formed byadjacent wall panels.

FIG. 18 is a cross sectional elevation detail of a roof constructionaccording to an aspect of the invention showing a ridge formed byadjacent roof panels.

FIG. 19 is a cross sectional view of adjacent roof panels illustratingan embodiment of a connection means there-between.

FIGS. 20 to 27 illustrate an example of a building construction methodaccording to an embodiment of the invention.

FIG. 28 is a top cross sectional view of a panel assembly showing acorner joint connection according to another aspect of the invention.

FIG. 29 is a detail top cross sectional view of a panel assembly showingone of the corner joint connections of FIG. 28.

FIG. 30 is an elevational view along the line A-A of FIG. 29.

FIG. 31 is a top cross sectional view of a corner wall joint formed bytwo adjacent composite panels according to another aspect of theinvention.

FIG. 32 is a cross sectional elevation detail of a wall constructionaccording to another aspect of the invention.

FIG. 33 is a cross sectional elevation detail of a roof constructionaccording to another aspect of the invention showing a ridge formed byadjacent roof panels.

FIG. 34 is a cross sectional elevation detail of a roof constructionaccording to another aspect of the invention showing a connection systemfor connecting a roof panel to a wall panel.

FIG. 35 is a cross sectional elevation detail of a roof constructionaccording to another aspect of the invention showing a connection systemfor connecting adjacent roof panels.

FIG. 36 is a cross sectional elevation detail of a wall constructionaccording to another aspect of the invention showing a connection systemfor connecting a wall panel to a base.

FIGS. 37 and 38 are cross sectional elevations of “I” beams formed withpanels according to another aspect of the invention.

In the appended drawings, like numbers are used to identify likeelements. In some cases, where one element is similar to but a variantof a previously shown element, the same reference numeral is used butwith suffix letters to distinguish the two.

DETAILED DESCRIPTION OF THE INVENTION

The invention is based on a system for constructing a structure, orbuilding, that incorporates a plurality of composite panels that arejoined together to form an enclosure. The system also includes variousjoint, or connecting elements or components for joining the panels. Asdiscussed further below, the connecting elements are designed accordingto the region of the joint. With such a modular system, the structuresformed with the invention are capable of being quickly erected and,where necessary, disassembled. The system of the invention may beprovided in the form of a kit and such aspect will be assumed to beencompassed by the invention.

Various types of composite panels may be used with the invention.However, in a preferred embodiment, the invention comprises the use of apanel as shown in FIG. 1. As shown, the panel 10 comprises a core 12made of a rigid foam material. Various types of foam materials can beused in the panels of the invention. In general, the foam preferable hasa closed cell structure and is sufficiently rigid so as to prevent thepanel from bending or otherwise deforming. Some examples of foams thatcan be used in the present invention include thermoplastic foams,thermoset foams, metallic cellular sections, paper core sections etc. Aswill be understood, the densities of the foams used in the panels of theinvention can be tailored depending upon the need. For example, insituations where a higher degree of load bearing strength is required,the foam used may be of a higher density. It will also be understoodthat the depth of the foam core 12 may also be varied to provide desiredstrength characteristics.

As also shown in FIG. 1, the panel 10 also includes two cover layers 14and 16, provided on opposed planar surfaces of the foam core. Asillustrated in FIG. 1, the cover layers 14 and 16 are provided on thecore 12 to form a laminate, or “sandwich” structure. The cover layers 14and 16 may, independently or together, be formed of various materials.For examples, the layers may comprise metal or wood sheathing or aplastic material. In the latter case, the layers 14 and 16 may comprisethe same or different thermoplastic or thermoset polymers, including,but not limited to, polyester, urethane, epoxy, polypropylene, polyethylene, polyvinylchloride etc. In one embodiment, where the panels areused for housing, the layers 14 and 16 preferably comprise polymersheets. In situations where the cover layers comprise a plasticmaterial, such plastics may be reinforced with various additivecomponents such as fibres (e.g. glass fibres), basalt, aramid etc.

In one embodiment, the panel 10 of the invention comprises a polymerfoam core with polymer cover layers 14 and 16. More preferably, thecover layers are fibre reinforced. In a further preferred aspect, thefibre reinforcement comprises a scrim material such as fibreglass scrim.Other such reinforcement fibres or materials will be known to personsskilled in the art.

The cover layers 14 and 16 are also preferably affixed to the surfacesof the foam core 12. This can be achieved in a number of ways such as byknown heat lamination methods wherein an adhesive applied to one of thefoam core or cover layer surfaces is heat activated. The adhesive canalso be applied in a liquid form, such as by coating or spraying anadhesive layer onto either the foam core and/or cover layer surfaces. Apreferred method of forming the panels of the invention is illustratedin FIG. 2. As shown, the panel 10 of the invention is formed by passinga sheet of rigid foam material 12 through a press nip formed by tworollers 18. Supply rollers 20 a and 20 b provide the cover layers 14 and16 on both sides of the foam core 12. The rollers 18 a and 18 b serve topress the two layers 14 and 16, respectively, against the oppositesurfaces of the foam core 12. The formed panel 10 is then passed througha laminating press 22 for forming a bonded surface between the foam core12 and the respective cover layer 14 and 16.

Although a description is provided above of a preferred method ofmanufacturing the panels of the invention, it will be understood thatthe panels for use in the building system discussed herein may bemanufactured using any other known method.

In a further embodiment of the invention the cover layers 14 and 16described above may be replaced with separate composite layers. Such anembodiment is shown in FIG. 1 a, wherein the panel 10′ is shownincluding a core 12, or “main core”, essentially as described above.That is, the main core 12 generally comprises a rigid foam material.However, in FIG. 1 a, the main core 12 is covered with composite panels11 and 13. Each of the cover panels 11 a and 11 b comprise a foam core,or “sub core”. 13 a and 13 b, respectively. The sub cores 13 a and 13 bare also formed of a foam material as used for the main core 12.However, as illustrated in FIG. 1 a, the sub cores 13 a and 13 b aregenerally of a reduced thickness as compared to the main core 12. Thesub cores 13 a and 13 b are covered by external cover layers 15 a and 15b, respectively. The cores 13 a and 13 b are also covered by internalcover layers 17 a and 17 b, respectively. The term “external” and“internal” as used in connection with FIG. 1 a refers to the positioningof the cover layers 15 a, 15 b and 17 a, 17 b with respect to the maincore 12. Specifically, the “external” layers 15 a and 15 b arepositioned opposite to the main core 12 so as to form the externalsurfaces of the panel 10′. Similarly, the “internal” layers 17 a and 17b are positioned between the main foam core 12 and the sub cores 13 aand 13 b, respectively. The composition of the sub cores 13 a and 13 bmay be the same or different depending on the specific need and each mayalso, independently, comprise the same or different material as is usedto form the main core 12. Similarly, the external and internal coverlayers 15 a, 15 b and 17 a, 17 b, may also, independently of each other,be formed of the same or different materials, with such materials beingchosen from those described herein with respect to layers 14 and 16.

It will be understood that a panel as shown in FIG. 1 b would offerseveral advantages. For example, such a panel would have greaterstiffness as compared to the panel of FIG. 1 and would also be lesssusceptible to damage as the internal foam core 12 would be protected byadditional layers of material. In addition, the use of three foam coresoffers increased insulation value.

Although the following discussion will refer to panels having thestructure shown and described in reference to FIG. 1, it will beunderstood that the panels shown and described in reference to FIG. 1 amay be used in the same manner wherever required.

Once the panels are formed, they may be used for forming walls, floors,and roofs. Although such panels can be joined together in various waysas known in the art, the invention provides a unique assembly systemincorporating connecting elements or joint components. In a preferredembodiment, the attachment of panels involves the use of molded,extruded or cast components that are designed to attach to the ends ofthe panels. Further details of the structure of these components areprovided below. The joint, or connecting components may be formed ofvarious materials as will be apparent to persons skilled in the arthaving regard to the present disclosure. For example, the components maybe formed from metals, such as aluminum, or various polymers. In thelatter instance, the polymer materials may be reinforced with fibresetc. to provided any desired physical properties (such as strength,stiffness etc.). As also discussed below, the joint or connectingcomponents or elements may be solid or hollow structures.

FIG. 3 illustrates one aspect of the invention wherein two panels 10 aand 10 b are provided in a linear, end to end manner to form a wallsection. Each of the panels includes respective cover layers 14 a, 16 aand 14 b, 16 b. As shown in FIG. 3, the layers 14 a and 14 b aredirected internally and may therefore be referred to as internal covers.Similarly, the layers 16 a and 16 b are face outwardly of the buildingand may therefore be referred to as external covers. As will beunderstood, the internal covers may differ in composition from theexternal covers. The respective internal and external cover layers maycomprise any type of suitable coating that is adapted to receivesuitable paint, colouring, or other surface that may be affixed theretoor provided thereon. Similarly, where one of the covers, such as theexternal cover, is exposed to the elements, the composition of same maybe adapted to withstand exposure to heat and cold, wind, or solarradiation etc. Further, the internal cover layer may be adapted toreceive, if needed, typical wall coverings such as paint or drywall etc.In one example, the outer layers 16 a and 16 b may comprise plywood or aplywood sheathing overlying a polymer layer. It will be understood thatvarious combinations and types of materials may be used for therespective internal and external coverings. Since the panels 10 a and 10b are used to form a section of a contiguous wall, it will be understoodthat the core portions of each would generally be of the samecomposition. In one example, the cores of the panels may be chosen toprovide a desired amount of thermal insulation. For the purpose of thesystem of the invention, and as discussed above, it will be understoodthat the core and cover layers of the various panels described hereinwill have the sufficient degree of strength and stiffness to allow thepanels to form a building. The parameters for designing the panels tomeet these requirements will be known to persons skilled in the art.

As shown in FIG. 3, in order to connect the ends of the panels, a walljoint, or connecting component 24 is used. Wall joint component 24generally comprises a “T” shaped structure, in end cross section, andincludes a first flange 26 and a second flange 28, extending generallyperpendicularly from the first flange. In the preferred embodiment, thesecond flange 28 has a length, measure from the first flange, that isgenerally equal to the thickness of the panels 10 a and 10 b. The firstflange includes an outer surface 30 and an inner surface 32. As shown inFIG. 3, the inner surface 32 is divided into two sections by the secondflange 26. Each of such sections is adapted to receive a portion of thepanels 10 a and 10 b. As shown, the outer surfaces of the panels 10 aand 10 b are placed in contact with the inner surface 32 of the firstflange 26. Further, the opposed ends of the panels 10 a and 10 b arearranged to abut the second flange 26. In one embodiment, an adhesivemay be used to secure the outer surfaces of the panels 10 a and 10 b tothe inner surface of the first flange 26. In one example, as shown inFIG. 3, such adhesive may comprise a sealing tape 34. It will beunderstood that forming a seal at the joint of two panels is preferredin order to prevent ingress of moisture or insects etc. and egress ofheat through the joint. Similarly, if needed, a further sealing tape orsuch may be used to secure the ends of the panels to the respectivesurfaces of the second flange. However, as will be understood, such endsof the panels would primarily comprise the foam core component and, assuch, a sealing tape may not provide the same level of sealing.

The wall joint component 24 preferably includes an inner plate 36 orcap, which is provided against the inner surface of the panels 10 a and10 b. As mentioned above, the second flange 28 is generally of the samelength as the thickness of the panels 10 a and 10 b. In sucharrangement, as shown in FIG. 3, the end of the second flange 28,opposite the first flange, 26, is generally flush with the inner facesof the panels 10 a and 10 b. Thus, the plate 36 can be arranged so as toabut portions of the inner faces of the panels 10 a and 10 b as well asthe end of the second flange 28. This arrangement is shown in FIG. 3. Inthis arrangement, fasteners 38 can be extended through the plate 36 anddirectly into the second flange 28. Such fasteners may comprise, forexample, nails or screws. Similarly additional fasteners may connect theplate 26 to the first flange 26 by passing such fasteners through therespective panel sections, adjacent the second flange 28. If needed,adhesives or sealing tape etc. (not shown) may be provided at contactpoints between the plate 36 and the respective panels 10 a and 10 b tosecure the plate 36 or to provide additional sealing at the jointbetween the panels. As will be understood, the wall joint component 24will be vertically oriented when in use. The component may be providedin specified lengths or may be cut to a desired length at the site ofthe building being constructed. Preferably, the wall joint component 24comprises a single elongate unit so as to form contiguous joint betweenadjacent wall panels. In one embodiment, the wall joint component 24 maybe formed as a single body, wherein the plate 36 is formed as part ofthe second flange 28. As can be understood from FIG. 3, in such anarrangement the wall joint component will comprise oppositely directedslots for receiving the ends of adjacent panels. In another embodiment,the wall joint component 24 may comprise several sections that areconnected together. Such an arrangement may be used, for example, wherea single segment is too large for transportation or handling etc.

FIG. 4 illustrates a corner joint between two wall panels 10 a and 10 b.In this case, the panels are connected together by means of a cornerjoint, or connecting component 40. As shown in FIG. 4, the corner jointcomponent comprises two slots 42 and 44, adapted to receive panels 10 aand 10 b, respectively. The slots 42 and 44 are generally arranged at a90° orientation to each other so as to form an orthogonal corner.However, it will be understood that where any other angle is desired ata corner, a respectively designed corner joint component can be used.However, for typical construction, a 90° orientation will be understoodto predominate. As shown in FIG. 4, the slots 42 and 44 are sized toenable a portion of the respective panels 10 a and 10 b to be receivedtherein. Once in place, fasteners 46 can be used to secure the panels tothe corner joint component 40. As with the previous component, it willbe understood that various types or combinations of sealing and adhesivedevices may be used to seal the contact surfaces between the panels 10 aand 10 b and the corner joint component 40. Although FIG. 4 shows thepreferred corner joint component 40 as comprising an elongate unitarybody, it will be understood that the inner, “L” shaped segment 49 of thecomponent may be formed as a separate body, in a manner similar to theplate 36 discussed above.

FIGS. 5-7 illustrate the use of the panels of the invention in formingroofs of the buildings. In particular, FIGS. 5-7 illustrate the jointformed at the upper end of a wall panel 10 a and a similar panel 10 cused for forming a roof. As before, each of the panels 10 a and 10 cinclude inner layers, 14 a and 14 c, and outer layers 16 a and 16 c. Thepanels also include cores 12 a and 12 c. As discussed above, the innerand outer layers 14 and 16 may be chosen from appropriate materials thatserve the desired purpose. The layers 14 a and 16 a for the wall panel10 a were discussed previously. The same materials may also be chosenfor the layers 14 c and 16 c of the roof panel 10 c. However, it will beunderstood that due to the different role of the roof panels 10 c, thelayers may be chosen from different materials. For example, the outerlayer 16 c of the roof panel 10 c may be designed with a material toprovide required water penetration resistance. In one example, the outerlayer 16 c may comprise a metal sheet. The core sections 12 a and 12 cmay also be of the same or different materials. For example, due to thefact that the roof panels 10 c will need to support loads appliedagainst its planar surface, the stiffness of such panels may need to begreater than that for the wall panels 10 a. Thus, the core 12 c andcover layers 14 c and 16 c may be formed of the required materials toprovide the required physical characteristics.

As shown in FIG. 5, a roof joint, or connecting component 50 is providedfor connecting a roof panel 10 c to a generally vertically oriented wallpanel 10 a. As shown in FIG. 5, the roof joint component 50 is designedto provide an angular arrangement between the generally vertical wallpanel 10 a and the roof panel 10 c. As will be understood, such anarrangement provides the roof with a pitch so as to facilitate water runoff etc. It will also be understood that the roof joint component 50 maybe designed to provide any degree of pitch for the roof of the buildingbeing constructed. It will also be understood that roof joint component50 comprises an elongate structure that preferably extends the length ofthe wall. However, in cases of very long walls, it will be understoodthat the roof joint component 50 may be provided in sections that can besecured together so as to form a contiguous structure.

The roof joint component 50 includes a first end 52 adapted to connectwith the upper edge of a wall panel 10 a and a second end 54 adapted toconnect with one edge of a roof panel 10 c. The first end 52 of the roofjoint component 50 preferably includes a slot 56 for receiving the upperedge of the wall panel 10 a. The slot 56 will be sized accordingly toreceive the wall panel edge. The roof joint component 50 and the wallpanel 10 a may be secured together using fasteners 58. In one preferredembodiment, the fasteners extend between opposite ends of the slot 56and through a portion of the wall panel 10 a received within such slot.As described previously, various adhesives or sealing members etc. maybe used to form a seal between one or more contact surfaces of the roofjoint component 50 and the wall panel 10 a.

The second end 54 of the roof joint component 50 includes a bearingsurface comprising a ledge 60, adapted to receive one edge of a roofpanel 10 c, and an edge 62 extending above the ledge 60, adapted tobrace against the end of the roof panel 10 c received on the ledge 60.It will be understood that adhesives or sealing members may be providedbetween the contact surfaces of the roof panel 10 c and the roof jointcomponent 50.

In a preferred aspect of the invention, the roof panel 10 c is providedwith an external cover layer 16 c that extends beyond the core 12 c andinner cover layer 14 c. As shown in FIG. 5, the external cover layer 16c extension 64 overlaps the upper edge 66 of the second end 54 of theroof joint component 50 and, therefore, the seam between the roof panel10 c and the component 50. As will be understood, with such anarrangement, a continuous layer is formed across the surface of theroof, thereby allowing for water drainage over the roof while preventingseepage into the joint between the roof panel 10 c and the roof jointcomponent 50.

The roof panel 10 c may be connected to the roof joint component 50 invarious ways. However, in one aspect, as shown in FIG. 5, suchconnection may be achieved with fasteners 68 that extend through theextension 64 of the external layer 16 c of the roof panel 10 c and intothe upper edge 66 of the roof component second end 54.

As indicated above, the embodiment illustrated in FIG. 5 shows a roofjoint component 50 that is designed to provide an angular arrangementbetween the generally vertical wall panel 10 a and the roof panel 10 c.It will be appreciated that such angular arrangement can comprise anydesired pitch for the roof. Thus, depending upon the design of thestructure being erected, the roof joint component can be adapted toprovide the require angular arrangement between the wall and roof panels(i.e. the pitch of the roof). In one extreme, the roof may have nopitch. That is, the roof would be flat and, for this purpose, the ledge60 would be orthogonal to the wall panel 10 a. Thus, the roof panel 10 cresting on the ledge 60 would also be orthogonal to the wall panel 10 a.

It will be appreciated that the span and pitch of the roof panelsdescribed above will depend on the expected loads to be supported. Insome cases, where the size of the building is larger than the panels,the roof may need to be composed of more than one panel as measured fromone wall to another. In such cases, a connecting member similar to thewall joint component shown in FIG. 3 may be used to connect adjacentroof panels together. It should be noted that a seam between roof panelsmay result in a zone of weakness, particularly where the roof is flat,and, accordingly, suitable reinforcement means may be provided tocompensate. For example, a beam or other such component may be providedto support such seams. Typically, for small buildings, such as singleroom structures, it may be possible for the walls and roof to be formedfrom single panel sheets. In the case of a gabled roof, such as shown inFIG. 5 and as discussed further below, two oppositely directed panelswould be required. Various orientations and configurations of the panelsare therefore possible according to the invention.

FIG. 6 illustrates the connection of two roof panels 10 c and 10 d,forming a ridge 70 of a roof at a gable end thereof. As discussed above,first ends 72 c and 72 d of respective roof panels 10 c and 10 d areconnected to respective roof joint components 50 c and 50 d. The roofpanels 10 c and 10 d also include respective second ends 73 c and 73 d,which are opposite to first ends 72 c and 72 d. The seconds ends 73 c,73 d are joined by a ridge beam component 80. The ridge beam component80 includes oppositely directed ledges 82 c and 82 d, which are adaptedto receive the second ends 73 c and 73 d of the respective roof panels10 c and 10 d. As will be understood the ledges 82 c and 82 d of theridge beam component 80 are provided in an angular format wherein eachledge is sloped downwardly and away from the center of the component 80.Such an angular arrangement corresponds to the pitch of the respectiveroof panels 10 c and 10 d.

The ridge beam component 80 will be understood to comprise an elongatemember that, in one aspect, extends the length of the building beingconstructed. The beam component 80 can, if necessary, be provided insections. The ridge beam component 80 also preferably includes anelongate cap 84, which overlies an upper end 86 of the ridge beamcomponent 80 and also overlaps a portion of the second ends 73 c and 73d of the roof panels 10 c and 10 d. As will be understood, in such anarrangement, water drainage is conducted over the cap 84 and across theseam formed between the roof panels 10 c and 10 d and the ridge beamcomponent 80. This therefore serves to prevent water seepage into suchseam.

The cap 84 may be secured to the roof assembly by various means. Forexample, fasteners 88 may be provided through the cap 84 and into theupper end 86 of the ridge beam component 80. In addition, sealing tape90 or other such sealing or adhesive member may be provided between theupper edge of the roof panels 10 c and 10 d and the contacted undersideof the cap 84.

As mentioned above, the roof assembly shown in FIG. 6 comprises a gableend of the structure being erected. As such, the roof assembly alsopreferably includes one or more pairs of gable beam components, or gablebeams, 92 c and 92 d, each extending from the respective roof jointcomponent 50 c and 50 d. As shown, respective first ends, 94 c and 94 d,of the gable beams 92 c and 92 d, are joined or connected to the opposedinner surfaces of respective roof joint components 50 c and 50 d. Thegable beams 92 c,d have upper edges 96 c,d and lower edges 97 c,d thatare generally parallel with each other. In the result the gable beams 92c and 92 d generally follow the same angle as the pitch of the roofpanels 10 c and 10 d. Thus, second ends 98 c and 98 d of the gable beams92 c and 92 d meet to form an apex 100 of the roof.

In a preferred embodiment, the upper edges 96 c and 96 d of the gablebeams 92 c and 92 d are provided with respective notches that combine toform a trough 102 that is adapted to receive and support the ridge beamcomponent 80.

As will be understood, the roof structures illustrated in FIGS. 5 and 6serve to support and distribute the load of the roof to the walls of thestructures.

FIG. 7 illustrates a section of the gable plate 92 c as taken along theline A-A of FIG. 6 and shows the manner in which such gable plate isattached to the gable end wall panel, shown at 10 e. As shown, the roofpanel 10 e is attached to the gable plate 92 c in the same manner asdiscussed previously with respect to FIG. 5. As shown in FIG. 7, thegable plate 92 c includes a slot 56 e for receiving the upper edge ofthe wall panel 10 e in the same manner as described above. It will beunderstood that wall panel 10 e includes a facing profile that matchesthe gable end of the building being erected. The gable plate 92 cincludes a ledge 60 e that is adapted to receive the underside of theroof panel 10 c. The wall panel 10 e is secured to the gable plate 92 cby means of fasteners such as shown at 58 in FIGS. 6 and 7.

FIGS. 8 and 9 illustrate aspects of the invention that serve to supportthe base of the wall panels, shown as 10 a. The wall panels 10 a aresimilar to the wall panels discussed above. As shown in FIGS. 8 and 9,the wall panel 10 a is supported by a sill component 110. In particular,the sill component 110 includes a lower base portion 112 and an upperpanel supporting section 114. The base portion 112 may rest on theground 116 as shown in FIG. 8 or may rest upon a concrete slab 118 asshown in FIG. 9. Where the sill component 110 rests on the ground, itwould be preferred to utilize cross ties 120 as shown in FIG. 8 so as toprevent relative movement between opposite sill components 110. It willbe understood that the cross ties 120 may be provided only around theperimeter of the building or at certain distances along the length ofthe wall as may be needed to ensure the shape of the structure ismaintained. Where a concrete slab 118 is used, it would be preferred toincorporate a ledge 122 along the outer edge of the slab 118 in which toreceive the base 112 of the sill component 110. Such an arrangementprevents the sill 110 from resting directly on the ground. However, itwill be understood that the sill component 110 can equally rest on theground and the concrete slab can be provided along the inner surfacethereof. In a further alternative, the concrete slab 18 may be providedwith various forms of anchoring such as bolts, brackets and the like toreceive or engage the sill component 110.

In either case, where cross ties 120 or a concrete slab 118 is used, thesill component is preferably secured thereto by means of fasteners 124.For example, as shown in FIG. 8, fasteners 124 are driven through theouter surface 111 of the sill component 110 and into the cross tie 120.In FIG. 9, the fasteners 124 are similarly driven through the outersurface 111 of the sill component and into the concrete slab 118. In thelatter instance, a masonry anchor 126, as known in the art, may beprovided to receive and engage the fastener 124.

The sill component 110 and the cross ties 120 may be formed from thesame materials as the other connection components of the invention suchas the wall joint component, the roof joint component etc. As will beunderstood, the sill component comprises an elongate structure that mayrun the length of the wall with which it is associated. Where necessary,the sill component may be formed of two or more sections that areconnected together.

The upper end 114 of the sill component 110 includes an upwardly openingslot 128 that is adapted to receive a portion of the bottom end 130 ofthe wall panel 10 a. The wall panel 10 a may be secured within the slot128 using adhesives or sealing tape etc. as discussed above. The wallpanel 10 a may be secured to the sill component using fasteners 131. Ina preferred embodiment, the fasteners 131 extend from one side of theslot 128 to the other and through the wall panel 10 a. It will beunderstood that any length of the wall panel 10 a can be inserted intothe slot 128. The length of insertion would depend upon the size of theslot. It will also be understood that the slot 128 aids in stabilizingthe wall panels 10 a and, therefore, the structure formed therewith.

FIGS. 10 to 12 illustrate the use of the composite panels of theinvention as flooring panels. FIG. 10 illustrates an aspect of theinvention wherein a sill component 110 such as that shown in FIG. 8 or 9is used to support wall panel 10 a. The invention provides for the useof joists 134 that extend between opposite sill components 110 (FIG. 10shows only one sill component for convenience; however, it will beunderstood that the opposite sill would be of the same configuration buta mirror image of that shown in the figure). Fasteners 136 are used toconnect the sill components 110 to the ends of the joists 134. As shown,the fasteners are preferably secured by insertion through the externalsurface of the sill component and into the ends of the joists 134. Itwill be understood that all fasteners described herein may comprisenails, screws, bolts or any other such known component or device.

The joists 134 may be formed from any of the same material as thevarious joint components and sill components mentioned above. That is,the joists 134 may be formed as an extrusion and may be provided to thejob site as elongate units of a desired size. Alternatively, the joists134 may be cut to the size requirements of the building.

The joists 134 shown in FIG. 10 are arranged in a known manner as iscommonly done in the field of construction. Once the joists 134 havebeen installed, composite flooring panels 10 f may be laid there-over.The flooring panels 10 f are constructed generally in the same manner asthe other panels described above. That is, the flooring panels 10 fcomprise a foam core 12 f having on opposing surfaces thereof, facing orcovering layers 14 f and 16 f. In the view shown in FIG. 10, the lowersurface 14 f is placed over the joists 134 while the upper surface 16 fserves as the exposed, floor surface. As before, the foam core 12 f canbe designed to have any desired level of density. The cover layers 14 fand 16 f may comprise the same or different materials. For example, thelower surface, 14 f may comprise a polymer sheet (as described above)while the upper layer 16 f may comprise plywood, OSB or other such knownflooring material. It will be understood that the material used for thelayers 14 f and 16 f may be chosen based on the specific need. In oneaspect, the upper layer 16 f may be provided with a finishing layer orfilm in order to accommodate traffic thereon or to receive a furtherfloor covering (e.g. tile, carpet, etc.)

The composite floor panels 10 f may be secured to the joists 134 usingvarious types or combinations of fasteners or adhesives etc.

FIG. 11 illustrates a variation of the assembly shown in FIG. 10. InFIG. 11, the sill component 110 a is generally the same as sillcomponent 110 of FIG. 10 but is provided with a ledge 138, which servesas a support for an edge portion of the composite floor panel 10 f. Thefloor panel 10 f may then be secured to the ledge 138 using fasteners140 and/or adhesives etc. The joists 134 a are also similar to thejoists described above with respect to FIG. 10; however, as shown inFIG. 11, these components may be designed to accommodate the ledge 138.It will be understood that the size of the ledge 138 may be varieddepending on the amount of the floor panel 10 f that needs to besupported.

FIG. 12 illustrates the sill component 110 a of FIG. 11 in a sectionwhere no joist is used. As shown, the ledge 138 is adapted to receive anedge portion of the floor panel 10 f.

Typically, the composite floor panels will be provided in specificsizes. Therefore, when a floor is being constructed, it is expected thatmore than one panel will be needed. In such case, the floor panels canbe provided over the joists 134 or 134 a as described above. FIG. 13illustrates the manner in which adjacent composite floor panels, shownas 10 f and 10 g, may be supported on a joist 134 to form the floor of abuilding. It will be understood that the joist in FIG. 13 is identifiedwith the reference numeral 134 for convenience only and that any othertype of joist as described herein (such as joist 134 a) may be used. Asshown, the joists 134 are positioned as specific locations on the regionof the floor so as to lie under adjacent edges 142 and 144 of therespective panels 10 f and 10 g. The edges 142 and 144 are thussupported on the joist 134. Fasteners 146 may then be used to secure theedges 142 and 144 to the joist 134. The fasteners 146 are extendedthrough the panels 10 f and 10 g and into the joist 134. It will beunderstood that adhesive or sealing tape etc. may also be used to securethe panels to the joist. In a preferred aspect, a joint cap 148 may beprovided to cover the seam between the adjacent panels 10 f and 10 g. Aswill be understood, the joint cap 148 serves to seal the seam betweenthe panels. The joint cap 148 may be secured over the edges 142 and 144of the panels 10 f and 10 g using adhesives etc. In one aspect,fasteners 149 may be used to secure the joint cap. The fasteners 149would preferably extend into the joist 134. In one aspect, the joint cap148 may be provided with a countersunk hold to receive a head of thefastener 149 so as to avoid protrusion above the level of the joint cap.

The building system of the invention as described above and as shown inFIGS. 3 to 13 is particularly suited for erecting temporary shelterssuch as sheds, hunting blinds, cabins and the like. The system can, forexample, be used to erect temporary dwellings in emergency situationsdisplacement of people in the event of natural disasters etc. Themodular nature of the panels and related components allows the system ofthe invention to be easily transported to a site where assembly of thebuilding using the various components can be conducted. It will beunderstood that the sizes of the panels and components can bepre-determined so that a building of a given size can be erected withoutany cutting of panels or the related structural components. Further,since the panels of the invention are mainly composed of a foam core,they are generally lightweight in nature thereby facilitating theconstruction process. Further, it will be appreciated the same panelscan be used for either walls, roof or floor of the building. Therefore,the system of the invention can be designed with only a single paneldesign, which will serve multiple purposes. It will be understood thatthis feature greatly simplifies the assembly process since the need forspecific, single purpose panels is obviated.

Where needed or desired, the panels of the invention can also bedesigned to include doors, windows, access opening or vents and thelike. For example, in the case of doors, certain panels can be designedto include a doorway opening and a door may comprise any type ofmaterial joined to the doorway by a hinge (for example a mechanicalhinge or a “living” hinge). Various types of insulation and/orweatherproofing can be incorporated to ensure the doors or windows areadequately sealed. Similarly, window openings may be provided by addinga clear glazing material in an opening, with such glazing being fixed inposition by any type of method (e.g. mechanical, welding, adhesivesetc.)

The external and internal surfaces of the layers of the panels may beprovided with coloring or various types of “skins” to provide aestheticor functional characteristics. For example, the skin may serve tofacilitate maintenance (i.e. cleaning) or to provide camouflage. In thecase of where the system of the invention is used to erect huntingblinds, the external and internal surfaces may have different patternedcamouflage graphics. In this way, the panels can be configured in twoalternate configurations such as a forest camouflage for forest huntingor a wetlands camouflage for waterfowl hunting. Thus, the system of theinvention can be designed to serve multiple purposes thereby providinggreater flexibility of use.

In the above discussion, emphasis was placed on using the system of theinvention to erect temporary or emergency structures. However, asdiscussed further below, the invention can equally be used to erect morepermanent, low cost modular housing or other such structures.

FIG. 14 illustrates schematically some of the elements of a system inaccordance with another aspect of the invention. As shown, a generalizedstructure 200 includes a number of wall panels 202 and a number of roofpanels 204. The wall panels 202 rest on base plate or sill components206. At the corners of the structure 200, corner joint components 207connect the adjacent wall panels 202 forming the corner. Roof jointcomponents 208 serve to connect wall panels 202 to roof panels 204.Ridge components 210 serve to connect roof panels 204 at a location ofthe ridge forming the roof of the structure. As discussed above, in somecases, the ridge component may be omitted, such as where a flat roof isdesired.

The structure of the wall and roof panels, 202 and 204, is generally thesame as that described above. Similarly, the various joint componentsare also made of the same general materials as described above.

The base plate or sill component 206 according to the aspect of theinvention comprises a generally “U” shaped member defining a slot 212into which bottom portions of the wall panels 202 are received. The roofjoint, or connecting component 208 is generally of the sameconfiguration as described above (such as with regard to FIGS. 8 to 12)and includes a slot 214 for receiving top portions of the wall panels202 and a ledge 216 for receiving edge portions of roof panels 204. Theridge joint component 210 according to this aspect of the inventioncomprises a generally “C” shaped structure defining a slot 218 that isadapted to receive edge portions of roof panels 204. As shown, the slot218 of the ridge component 210 is angularly provided in a mannercorresponding to the pitch of the roof as will be understood by personsskilled in the art.

FIG. 15 illustrates the use of a wall panel 202 of the invention withtypical concrete foundation walls 220. As shown, in constructing a wall,one or more sill components 206 are first secured to typical wood joists222 in a manner known in the art. The joists 222 are secured to thefoundation wall 220 as is typically done. Following this, wall panels202 are placed into the slot 212 of the sill components 206. It will beunderstood that the sill components 206 will generally be providedaround the perimeter of the foundation wall.

As mentioned above, the composite wall panel 202 shown in FIG. 15 is ofthe same general construction as described above. The panel 202 includesa rigid foam core 224 composed, for example, of a foamed polymer.Further, as with all composite panels of the present invention, the foammay be designed to provide desired heat and/or sound insulationproperties by adjusting the density of the foam and/or the thickness ofthe core itself. For example, when used for forming walls, the compositepanel may comprise a foam core made of expanded polystyrene foam and maycomprise a thickness of 6 inches. The overall dimensions of the panelitself may vary depending on the desired size. Although large panelswould be preferable so as to limit the number of seams in the wall, suchpanels may be difficult to transport and manipulate. Further, providingpanels of “standard” sizes, such as 4 feet×8 feet, construction of thebuilding would be easier.

The foam core 224 is provided with cover layers or skins, comprising afirst layer 226, which faces the inside of the building being erected,and a second layer 228, which faces the externally facing side of thepanel. As discussed above, the layers 226 and 228 may be the same ordifferent in composition as needed. For example, each of the coverlayers may comprise a polymer sheet adhered to the foam core material.Typically, when the building is erected, both of the layers 226 and 228may be provided with other covering or sheathing as may be needed ordesired. For example, as shown in FIG. 15, the inwardly facing layer,226, may be covered by drywall 230 or other known covering. Similarly,the externally facing layer 228 may be covered by siding 232 or othercommonly known external sheathing.

FIG. 16 illustrates a detail showing the construction of a building and,in particular, illustrating the connection between a composite panelwall and a composite panel roof according to an aspect of the invention.The detail shown in FIG. 16 may, for example, comprise the upper portionof the wall shown in FIG. 15. For this reason, the same numbering oflike elements will be used for convenience. In the embodiment shown inFIG. 16, the building is constructed using commonly known joists, suchas wood joists 233. For this reason, the composite wall panel 202 ispreferably provided with a wall cap 234, which may be similar instructure to the sill component 206 shown in FIG. 15. The wall cap 234may be connected to the upper end of the panel 202 using fasteners,adhesives or any combination thereof. It will also be understood thatsealing material such as tape or caulking may also be used. The joists233 are then provided to rest on the wall cap 234. In a preferredembodiment, the joists 233 may be provided with a slot or cut-out 236 tofit over and engage the wall cap 234.

FIG. 16 illustrates the composite roof panels 240 used for constructingthe roof of the building. As with the wall panels 202, the compositeroof panels 240 are also of the same construction as described above.Namely, the roof panels 240 comprise a rigid foam core 242 and innerfacing and outer facing cover layers, 244 and 246, respectively. As withthe wall panels, the foam core 242 of the roof panels 240 may bedesigned in terms density and dimensions, for various heat or soundinsulation properties. In one example, the core may comprise expandedpolystyrene foam of 8 inches in thickness. As described above, the coverlayers 244 and 246 may be of the same or different composition. Forexample, each of the cover layers 244 and 246 may comprise a polymersheet adhered to the foam core material. On the inner layer, standardsheathing material such as drywall 248 may be provided over the innerfacing cover layer 244. The outer facing layer 246 may comprise a metalsheet or such metal sheet may be provided as an external sheathing overa polymer outer facing layer. This discussion has focused on metal cladroofing. However, it will be understood that various types of roofingmay be provided on the building such as wood or asphalt shingles etc.The invention will be understood to not be limited to any particulartype of internal or external sheathing.

In FIGS. 5 to 7, the roof joint component was described as being aunitary structure having one end for engaging the top of a wall paneland another end for engaging an end of a roof panel. However, in theembodiment shown in FIG. 16, another embodiment of a roof joint, orconnecting component is shown at 250. This embodiment of the roof jointcomponent 250 includes a base 252 comprising a generally flat portionthat is adapted to be positioned atop the upper ends of the joists 233described above. The roof joint component 250 may be secured to thejoists 233 in various known ways such as with fasteners (e.g. nails),adhesives etc. The roof joint component 250 further includes a ledge 254adapted to receive the ends 255 of the roof panels 240. As shown in FIG.16, the ledge 254 preferably includes a shoulder 256 at the end adjacentthe outer portion of the wall. The shoulder 256 serves to act as a stopfor the roof panel ends 255. In the embodiment illustrated in FIG. 16,the ledge 254 and shoulder 256 are provided generally orthogonal to eachother. In this embodiment, it is shown that the outer ends 255 of theroof panels 240 are cut to fit within the space defined by the ledge 254and shoulder 256. The degree of cutting required will depend upon thepitch of the desired roof. For example, in the case where a flat roof isdesired, it will be understood that no cutting will be necessary.However, as shown in FIG. 16, where the roof is to include a certainpitch, the necessary angular cuts may be provided on the roof panels240.

The roof panels 240 may be secured to the roof joint component 150 usingone or more of fasteners, adhesives etc. In addition, one or more typesof anchors or flanges, such as the flange 258 shown in FIG. 16 may beincluded in the system of the invention to further secure the roofpanels 240 and/or to provide a surface for attaching the interiorsheathing.

In the above discussion, a description was provided of some corner jointcomponents, in the case of corners formed by wall panels, and ridgejoint components, in the case of roof ridges formed by roof panels.FIGS. 17 and 18 illustrate other embodiments of these components. InFIG. 17, another embodiment of a corner joint, or connecting component270, or corner post, is illustrated. As shown, the corner jointcomponent 270 serves to form or support a corner formed by adjacentcomposite wall panels 202 a and 202 b. The structure of the panels 202 aand 202 b is as described above. The corner joint component 270 includesopposed slots 272 and 274 adapted to receive panels 202 a and 202 b,respectively. The slots 272 and 274 in the embodiment shown in FIG. 17are shown as including angular base sections to receive the ends of thepanels 202 a and 202 b after such panels are cut to include bevelledends. It will be understood that the corner joint component 270 mayalternatively include slots of the same configuration as shown in FIG.4. The panels 202 a and 202 b may be secured to the corner jointcomponent 270 in any manner as described above.

As also shown in FIG. 17, the outer edges of the corner joint componentmay extend beyond the outer cover layer of the panels and, thereby, asan edge against which any desired and optional external cladding, suchas siding, shingles etc. may abut.

FIG. 18 illustrates a ridge joint, or connecting component 280, which isused to join opposing composite roof panels 240 a and 240 b to form apitched roof. The structure of the roof panels 240 a and 240 b is thesame as that described above. The ridge joint component 280 includesopposing slots 282 and 284 for receiving opposed ends of roof panels 240a and 240 b, respectively. As shown in FIG. 18, the slots 282 and 284are shaped to accommodate the ends of roof panels after being cut tomatch the desired pitch of the roof being constructed. It will beunderstood that the shape of the slots and the needed cutting of thepanel ends will vary based on the need and the desired roof pitch.

The corner joint component 270 and ridge joint component 280 aregenerally elongate structures and may be extruded from materials asdescribed above.

As discussed above, the composite panels used for forming the roof ofthe building may be of any dimensions. Although large sized panels wouldreduce the number of seams, such panels would be difficult tomanipulate, particularly when building the roof. Where seams betweenroof panels are present, various means of sealing same may be used. Someexamples have been described above. The invention provides anotheroption for connecting adjacent roof panels apart from the ridgeconnection previously described. One example of a roof constructionaccording to an aspect of the invention is shown in FIG. 19. In thisfigure, roof panels 300, 302 and 304 are shown. The faces of the panelsdirected towards the interior of the building are provided, in oneembodiment, with drywall sheets 306 a, b and c. The faces of the panelsdirected towards the exterior of the building are provided with metalsheathing 308 a, b and c. Each of the metal sheathing include externallyextending flanges 310. In order to connect adjacent roof panelstogether, a cap 312, having a generally inverted “U” shaped structurewhen in use, is provided over the adjacent flanges 310 of adjacentpanels. The caps 312 include fastening elements 314 that extend from thecap 312 and through the seam formed by adjacent panels, such as betweenpanels 300 and 302 and between panels 302 and 304. The joints betweenadjacent panels is secured by attaching tie plates 316 to the fasteningelements 314. As shown, the tie plates 316 are sized to overlap portionsof the adjacent panels. Thus, when secured to the fastening elements,the tie plates 316 and the caps 312 are urged together and locked. Aswill be understood, the interlocking of the inverted “U” shaped caps 312and the upwardly extending flanges 310 of the adjacent panels serve toprevent separation of adjacent panels. The tie plates 316 may be securedto the fastening elements 314 by various means. For example, at leastthe terminal portion of the fastening elements 314 may be provided withan external thread and cooperating nuts may be provided to secure thetie plates 316 thereto.

FIGS. 20 to 27 illustrate a method of how a building may be constructedusing, for example, the panels and joint components described above, andin particular, as shown in FIGS. 16 to 19. As shown in FIG. 20, aconcrete pad 400 is first poured in the location where the building isto be erected. Corner posts, or corner joint components 402 are thenprovided at the corners of the building. The corner posts 402 may beembedded in the concrete or may be secured to the formed concrete. Inthe next phase, wall panels 404 are inserted into the respective slotsin the corner posts 402. In FIG. 20, the walls are shown as being formedof a single panel 404. However, it will be understood that each wall maybe comprised of multiple panels where needed.

In FIG. 21, the building is shown having three walls erected. As shown,one wall 405, is provided with a gable shaped top portion. It will beunderstood that, if needed, all the panels may have the same shape asshown at 404.

FIGS. 22 and 23 illustrates the addition of wall caps, or wall capcomponents 406 to the upper ends of the wall panels 404 and theinstallation of ceiling joists 410. In this embodiment, the wall caps406 include slots 412 that are adapted to receive the ceiling joists412.

As shown in FIG. 24, once the wall caps 406 and ceiling joists 410 areinstalled, the roof joint, or connecting components 414 are then securedto the upper ends of the ceiling joists 410. In the embodiment shown,roof joint components 414 are only required on the two opposed wallssince the remaining two walls are shown as including gable ends. For thegable wall panels, gable joint components such as the gable plates 92 cand 92 d as described in reference to FIGS. 6 and 7, may be used. Asshown in FIG. 16, the roof joint component 414 include slots 416 forreceiving ends of roof panels. As shown in FIG. 7, similar engagementstructures are provided in the gable plates.

FIG. 25 illustrates the addition of roof framing members 418 and theinstallation of the ridge joint component 420. Ridge joint component 420is generally the same as that shown and described in FIG. 18.

FIG. 26 illustrates the next step wherein roof panels 422 are installed,with each panel extending longitudinally between the ridge jointcomponent 420 and respective roof joint component 414. As describedabove with regard to FIG. 19, the seams between adjacent panels 422would preferably be connected or locked in place.

Finally, in FIG. 27, the step of installing facia 424 or other types ofcommonly known covering is shown.

FIG. 4 discussed above illustrated one embodiment of connecting panelsthat form a corner between two panels, such as wall panels. A variationin the corner joint between two panels is illustrated in FIG. 28 to 30.In FIGS. 28-30, the panels of the invention will be understood as havingthe structure as described above. In FIGS. 28-30, the panels forming thecorner joint are adapted to be connected together by means of a pin andkeyhole arrangement, which serves to interlock the panels and to providethe building with further structural integrity to the building beingconstructed. FIG. 28 shows a plan view illustrating four walls forming abuilding. In construction, two opposing wall panels 500 and 502 arefirst erected in the manner described above. Subsequently, two opposingend wall panels 504 and 506 are positioned. As shown, the ends of eachwall and end wall panel are provided with cooperating profiles toprovide mutual engagement between adjacent panels. Specifically, asshown in FIG. 29, the wall panels are provided with internal cut-outsresulting in each end to have an “L” shaped structure. Thus, the ends ofeach pair of wall and end panels combine to form a corner having azigzag shaped joint there-between. As shown in FIGS. 28 and 29, theinternal faces 505 and 506 of the end panels 504 and 506 are sized to bereceived between the internal faces 501 and 503 of the two wall panels500 and 502.

As shown in FIGS. 29 and 30, the wall panels 500 and 502 are providedwith a number of keyholes 508 having a larger upper opening and anarrower lower opening. The end panels 504 and 506 are provided withpins 510 adapted to interact with the keyholes 508. More specifically,the pins 510 have heads that are capable of being inserted into thelarger opening of the keyholes 510 but not the narrower opening thereof.To further facilitate this arrangement, each of the panels 504 and 506may be provided with end caps as shown in FIG. 29 into which the pins510 and keyholes 508 are provided. In constructing the wall structureshown in FIG. 28, the end wall panels 504 and 506 are slightly liftedduring placement between wall panels 500 and 502 so as to insert thepins 510 into the larger openings of the respective keyholes 508. Theend wall panels 504 and 506 are then lowered, thereby engaging the pins510 within the respective keyholes 508. In such arrangement, it will beunderstood that the wall panels 500, 502, 504 and 506 will beinterlocked. In dismantling the building, the reverse process isfollowed. That is, once the roof structures have been removed, the endwall panels 504 and 506 are lifted slightly so as to draw the pins 510into the larger opening of the keyholes 508 and then laterally movedaway from the wall panels 500 and 502.

It will be understood that a similar pin and keyhole arrangement asdescribed in reference to FIGS. 28-30 may be used for any other cornerjoint of the panels of the invention. For example, such an arrangementmay be provided between wall and roof panels. It will be appreciatedthat in such example, connecting the respective pins and keyholes isfacilitated by the fact that the roof panels would generally be loweredonto existing wall panels and, therefore, insertion of pins on the roofpanels into corresponding keyholes in the wall panels is renderedpossible.

In the above description, various examples of connecting members havebeen described for connecting the panels of the invention in a number ofways. A few other examples of possible connecting members will now bedescribed with reference to FIGS. 31 to 36. As will be understood, anycombination of the connecting members disclosed herein can be used inthe invention depending on the specific need. The need or desirabilityof one component over another will be known to persons skilled in theart. Some considerations in the choice may include cost, speed ofconstruction, required structural integrity, etc., and combinationsthereof. The invention is not limited to any particular combination ofpanels or connecting components.

FIG. 31 illustrates a variant of a corner connection of two wall panelsaccording to another aspect of the invention. As with the embodimentshown in FIGS. 28 to 30, in the embodiment of FIG. 31, the panels areadapted to avoid the need for a separate corner joint component. Thatis, as shown, and using the numbering convention of FIGS. 28 to 30, thecorner arrangement of FIG. 31 comprises an intersection of two wallpanels 502 a and 504 a. The panels 502 a and 504 a are designed toinclude end reinforcement members 512 and 514, respectively.Reinforcement members 512 and 514 may comprise generally elongate,rectangular tubular members as shown in FIG. 31. For example,reinforcement member 512 is comprised of spaced apart side walls, 516and 517, which are connected by opposing end walls 518 and 519 to definea hollow interior. Similarly, reinforcement member 514 is comprised ofside walls 520 and 521, which are separated by end walls 522 and 523. Asshown, side walls 517 and 521 form the ends of the panels 502 a and 504a, respectively. Although reinforcement members 512 and 514 aredescribed as being hollow tubular members, it will be understood thatsuch structure may be preferred for a high strength to weight ratio.However, the reinforcement members may equally be solid structuresdepending upon the need. The reinforcement members may be made of anyvariety of materials such as metal, plastic, wood or any combinationthereof.

The reinforcement members 512 and 514 are positioned within each wallpanel so that the layers, or skins, of the panels 502 a and 504 a,extend over the end walls of the respective reinforcement members 512and 514 as shown in FIG. 31.

One of the pair of reinforcement members, for example 514, is providedwith a flange 524 that is connected to or, preferably, integral with endwall 522, which faces the outer side of the panel 505 a. Flange 524 issized to extend beyond the side wall 521 and, preferably, extends beyondthe side wall 521 a distance roughly equal to the thickness of theadjacent panel 502 a forming the corner structure. As shown in FIG. 31,when the panels 502 a and 504 a are arranged to form the corner, the endof panel 502 a is positioned within the corner formed by the flange 524and the side wall 521 of the reinforcement member 514. As also shown,the outer layer, or skin, 526 of the panel 504 a having the flange 524also preferably extends over the flange 524. In this way the outerappearance of the structure along the wall panel 504 a would appearwithout seams.

Various fasteners, 528, may be used to connect the wall panels 502 a and504 a together. In one aspect, the fasteners 528 may comprise nails,screws or the like, that are provided through the outer layer 526 andthe flange 524 of the panel 504 a and through the side wall 517 of theadjacent panel 502 a. In this way, the two panels are secured togetherto form a corner of a structure.

FIG. 32 illustrates a variant of the embodiment shown in FIGS. 5 and 16and shows a joint between a roof panel 550 and a wall panel 552. Thepanels 550 and 552 have the same general construction as describedabove, namely, comprising a core positioned between two layers or skins.The wall panel 552 includes an elongate reinforcement member 554positioned at the top edge of the panel 552. The reinforcement member isgenerally as described previously with respect to reinforcement members512 and 514.

In the embodiment of FIG. 32, the wall panel 552 is further providedwith a top plate 556, which includes a top wall 558, a bottom wall 560that are separated and joined by opposed side walls 562 and 564. Asshown, the bottom wall 560 includes an open channel. Side wall 564 isshorter that side wall 564 and is positioned facing outwardly of thestructure being erected. In the result, the top wall 558 is angularlyprovided with respect to the bottom wall 560. As will be understood bypersons skilled in the art having regard to the present specification,the angle provided for the top wall 558 will preferably correspond tothe pitch of the roof being erected. The top plate 556 may be connectedto the roof panel 550 by any means. By way of example, fasteners, suchas shown at 566 may be provided through the top wall 558 and into theroof panel 550.

The top plate is further preferably adapted to receive and retain thewall panel 552. For this purpose, the side walls 562 and 564 areprovided with downwardly extending flanges, 568 and 570, respectively.In this way, a channel is formed with the flanges 568 and 570 and theunderside of the bottom wall 560, which is preferably sized to receivethe upper end of the wall panel 552. Preferably, the length of theflanges 568 and 570 is sufficient enough to allow a surface throughwhich fasteners 572 may be extended. As shown, the fasteners 572preferably extend through the respective flange and the outer layers ofthe wall panel. As shown, the wall panel 552 is also provided with thereinforcement member 554. Thus, the fasteners 572 also extend throughthe adjacent wall of the reinforcement member 554. In this way, a corneris formed between the wall panels 550 and the wall panels 554.

The roof panel 550 also includes a reinforcement member shown at 574. Aswith the previously described reinforcement members, member 574 ispreferably an elongate hollow structure; however, the inventioncontemplates member 574 being solid as well. Similarly, member 574 maybe formed of any of the materials discussed above. The roof panelreinforcement member 574 includes an outer wall 576 and a lower wall578, which preferably form a generally 90° angle at the bottom, outsidecorner of the member 574. The outer wall 576 preferably includes agroove 580 on the upper end thereof. As shown, the groove 580 is adaptedto receive a hooking portion of a soffit element 582. Soffit element 582may be formed of any material as would be apparent to persons skilled inthe art. For example, soffit element 582 may comprise a sheet ofaluminum etc. The soffit element 582 may be secured to the roofreinforcement member 574 using, for example, fasteners 584 or the like.

The lower portion 586 of the soffit element extends towards the wallpanel 552. In a preferred embodiment, the lower edge of the flange 570extends outwardly away from the outer face 588 of wall panel 552,thereby defining a channel 590 for receiving a “hook” portion 592 of thesoffit. In this arrangement, the soffit is secured to the corner formedby the wall and roof panels.

One example of a ridge joint at the apex of a roof structure wasdescribed in connection with FIG. 18. FIG. 33 illustrates yet anotherembodiment of a roof ridge wherein the panels include reinforcementmembers, such as those shown in FIGS. 31 to 32. As shown in FIG. 33, apair of roof panels 600 and 602 are provided to form a roof. As with thepreviously described embodiment, the panels 600, 602 are arranged in anangular manner so as to form an apex, or ridge 603, on the roof. It willbe understood that the ridge 603 may assume any desired angle, or pitchand that such angle will depend on the desired drainage requirements,the span of the panels, any height clearance limitations etc. Theinvention is not limited to any specific pitch. As in the embodimentspreviously described, the panels 600 and 602 include respectivelongitudinal reinforcement members 604 and 606. As also described above,the reinforcement members 604, 606 may comprise hollow or solid,generally rectangular beams or elements which form the ends of therespective panels.

In the roof structure shown in FIG. 33, the ridge 603 is preferablyprovided over a bearing wall 608 for support. In one case, the bearingwall 608 is comprised of one or more of the wall panels of the inventionor may comprise a wall of commonly known construction as well. In apreferred embodiment, however, the bearing wall 608 shown in FIG. 33comprises a sandwich panel such as those described above. Further, inthe preferred embodiment, the panel 608 is provided with an elongatereinforcement member 610 that extends across the top edge of the panel608 and forms the top end thereof. As with the aforementionedreinforcement members, the member 610 may also be hollow or solid forthe same reasons provided above. The reinforcement member 610 isembedded within the top edge of panel 608 within the layers 611, 612thereof. The reinforcement member 610 is provided in one embodiment witha generally pentagonal cross shape in end cross section. That is, asshown in FIG. 33, the reinforcement member 610 includes a bottom wall614 that is positioned within the core of the panel 608. Side walls 616and 618 extend upwardly from the bottom wall 614, on opposite sidesthereof. As shown in FIG. 33, in a preferred embodiment, the side walls616 and 618 are covered by the respective layers 611 and 612. A top wallis comprised of two sections 620 a and 620 b that are angled upwardly toform an angle that preferably approximates the desired pitch of theroof. It will be understood that in some cases, the angle providedbetween the top wall sections 620 a and 620 b may not need to be that ofthe desired roof pitch. The apex of the top wall extends above thelayers 611 and 612 and includes a locating flange 622, the purpose ofwhich will be described below.

As illustrated in FIG. 33, in forming the roof, the ends of the roofpanels 600 and 602 are positioned in an opposed arrangement with theends thereof facing each other. The ends of the panels, formed byreinforcement members 604 and 606, respectively, are positioned on thereinforcement member 610 of the wall panel 608. As can be seen, theangle preferably formed by the top wall sections 620 a and 620 b of thereinforcement member 610 serves to align the roof panels 600 and 602 inthe desired pitch. The panels 600 and 602 are positioned on the top wallsections 620 a and 620 b such that the ends thereof abut the locatingflange 622. In one embodiment, such as shown in FIG. 33, opposed, lowerside walls 626 and 628 of the panels 600 and 602, respectively, areprovided with extended flanges 630 and 632. The flanges 630 and 632serve to assist the location of the panels 600 and 602 with respect tothe locating flange 622 and also to provide a surface through whichfasteners such as shown at 634 can be passed to secure the roof panels600, 602 to the reinforcement member 610 of the wall panel 608.

In order to close the ridge 603 of the roof, a ridge cap 636 isprovided. The ridge cap 636 generally comprises an elongate memberpreferably having opposed arms 638 and 639 angularly arranged so as toconform to the pitch of the roof being constructed. The arms areprovided with locating flanges 640, 641, respectively, which abut theends of the roof panels. The terminal ends of the arms 638, 639preferably extend over at least portion of the upper ends of thereinforcement members 604, 606 of the wall panels 600, 602. In this way,fasteners such as shown at 644 may be used to secure the ridge cap 636to the roof panels 600, 602. As will be understood, in addition to thefasteners mentioned above, any other means may be used to secure andseal the various members of the roof components together. These includeadditional fasteners, joint compounds, weather stripping, caulking,sealants and the like.

FIG. 34 illustrates a further mounting arrangement of roof structures,which has particular advantages in flat roof structures. As shown, aroof panel 650 is provided above a wall panel 652. The panels 650, 652will be understood to have the same general structure as describedabove. In this embodiment, the roof panel 650 is provided with tworeinforcement members 654 and 656. As discussed previously, thereinforcement members may have a solid or hollow structure and may bemade of a variety of materials. The first reinforcement member 654 isprovided at the terminal end of the wall panel and preferably forms theouter edge thereof. In the specific embodiment shown in FIG. 34, theouter edge of the roof panel 650 extends beyond the wall panel 652 so asto form a gable for the structure being constructed. It will beunderstood that the length of the gable may vary depending on the need.

The second reinforcement member 656 is provided internally within theroof panel 650 and is located at the position of the wall panel 652. Aswill be understood, reinforcement member 656 serves to provide astructural support at the load point where the roof panel 650 rests onthe upper edge of the wall panel 652. In one embodiment, the wall panelmay include a reinforcement member as described above. In such case, theconnection between the roof panel and wall panel may be accomplishedwith various types of fasteners and the like. For example, angle iron orsimilar components may be used. FIG. 34 provides a further means forfacilitating the connection process between the panels 650, 652. Asshown, the upper edge of the wall panel 652 is provided preferably witha generally rectangular “U” shaped reinforcement member 658, having abottom wall 660 and opposed side walls 662 and 664. The reinforcementmember 658 thereby forms a channel at the top edge of the wall panel652. Although a generally “U” shaped structure for the reinforcementmember 658 is preferred to form the channel, various other forms will beunderstood to provide the same result and such other forms arecontemplated by the invention. In a preferred embodiment, the channel ofthe reinforcement member 658 is sized, or adapted, to receive a mountingblock 666 that is attached to the roof panel 650. The mounting block 666includes an upper wall 668 and opposed, downwardly depending side walls670, 671. As shown, the mounting block 666 is first attached to thesecond reinforcement member 656 within the roof panel 650 by means offasteners 672 and the like, that are passed through the upper wall 668and into the second reinforcement member 656. Once the mounting block666 is attached to the roof panel 650, the roof panel 650 is thenlowered onto the wall panel 652 so as to insert the mounting block 666into the channel of the of the reinforcement member 658. In a preferredembodiment, as shown in FIG. 34, the side walls 670, 671 of the mountingblock 666 may be optionally provided with tapered lower ends so tofacilitate insertion of the mounting block 666 within the channel of thereinforcement member 658. Once the roof panel 650 is positioned,fasteners such as shown at 674 may be used to secure the roof and wallpanels together. As shown, the fasteners are provided through oppositesides of the wall panel 652 and extend through the side walls 662 and664 of the reinforcement member 658 and through the side walls 670 and671 of the mounting block 666.

FIG. 35 illustrates an embodiment of the invention wherein two abuttingpanels, such as roof panels 680, 682, are connected. Although referenceis made to roof panels, it will be understood that the followingdescription may equally apply to any of the aforementioned panels.However, it will be apparent to persons skilled in the art that thefollowing connection method may be particularly suited for roof panelapplications. As shown in FIG. 35, the roof panels 680 and 682 areprovided with respective reinforcement members 684 and 686, which willbe understood to have the same general characteristics as thereinforcement members previously described. However, for thisembodiment, the opposed outer walls 688 and 690, respectively, of thereinforcement members 684, 686 are provided with oppositely directedlocking flanges 692 and 694, respectively. As shown, the locking flanges692 and 694 are adapted, that is sized and arranged, to engage eachother when the panels 680, 682 are assembled together. The engagementbetween the locking flanges 692, 694 may be by a “snap fit” or any otherknown manner, such as by first providing one panel in an angledarrangement and the orienting such panel to the desired lineararrangement when the locking flanges 692, 694 engage each other. Inaddition, to form the required seals between the roof panels 680, 682,the opposite side walls of the reinforcement members may include sealingflanges that extend beyond the ends of the roof panels 680, 682. Forexample, as shown in FIG. 35, the lower side wall 696 of thereinforcement member 684 of one roof panel 680 is provided with asealing flange 698. Similarly, the upper side wall 700 of thereinforcement member 686 of the other roof panel 682 is also providedwith a sealing flange 702. When the panels 680, 682 are assembled, thesealing flanges 698, 702 overlap at least a portion of the reinforcementmembers 684, 686 of the opposed panel. To facilitate the overlapping ofthe sealing flanges 698, 702, the reinforcement members 684, 686 mayinclude respective recesses, such as shown at 704 and 706, to receivesuch sealing flanges 698, 702. Various attachment means such asfasteners 708 and the like, may be provided to connect the reinforcementmembers 684, 686 together. For example, as shown, the fasteners 708 maybe provided through the sealing flange 698 and through the adjacent wallof the opposite reinforcement member 686. In roof applications such asshown in FIG. 35, fasteners would preferably only be provided on theunderside of the panel assembly. The sealing flange on the upper surfaceof the roof panel assembly would then preferably be provided with anytype of sealing means to prevent ingress of moisture, insects, etc. asmay be needed. The invention is not limited to any particular sealingmeans.

FIG. 36 illustrates an embodiment of the invention wherein a wall panel720 is secured to a concrete base 722, such as a foundation wall or aconcrete slab etc. The embodiment illustrated in FIG. 36 provides ameans of securing the wall panel 720 to the concrete base 722. As shown,the bottom end of the wall panel 720 is provided with a reinforcementmember 724, which preferably a generally rectangular “U” shapedstructure, defining a channel. For example, the reinforcement member 724comprises a top wall 726 and downwardly depending side walls 728 and730. As will be understood, the reinforcement member 724 may compriseany other shape while still providing the aforementioned channel. Asalso shown, the reinforcement member 724 is also preferably providedwithin the wall panel 720, whereby the layers 732, 733, forming thepanel, extend over the side walls 728 and 730 of the reinforcementmember.

A mounting block 734 is provided on the concrete base 722 to which thewall panel 720 is to be secured. The mounting block 734 includes abottom wall 736 and opposed, upwardly extending side walls 738, 740. Themounting block 734 is secured to the concrete base 722 by insertinganchor bolts 742 through bolt holes (not shown) provided in the bottomwall 736. The anchor bolts 742 will be understood to preferably beprovided within the concrete before it hardens, in a manner that iscommonly known in the art. Once the anchor bolts 742 are inserted intothe aforementioned bolt holes in the bottom wall 736, and the after themounting block 734 is properly positioned, the mounting block 734 issecured in position by nuts 744 that are tightened on the bolts 742.

Once the mounting block 734 is secured to the concrete base 722, thewall panel 720 is lowered thereon so as to allow mounting block 734 tobe received within the channel provided by the reinforcement member 724.Once the wall is thus positioned, various fasteners 746 and the like maybe used to connect the wall panel 720 to the mounting block 734. Asshown, the fasteners 746 are able to extend through the layers 732, 733forming the panel 720, through the side walls 728, 730 of thereinforcement member 724, and through the side walls 738, 740 of themounting block 734. In this manner, the wall panel 720 is then securedto the mounting block 734 and, therefore, to the concrete base 722. Itwill be understood that reference has been made herein to concrete base722. However, as will be understood by persons skilled in the art, theconnection system described above can be used for any other base. Forexample, the base may comprise a floor panel such as described above ora wood panel. In such cases, the anchor bolt 742 will assume the neededstructure to enable the securing of the mounting block 734.

FIGS. 37 and 38 illustrate uses of panels of the present invention asjoists or I-beams, or similar structural support members. As shown inFIG. 37, an example of a joist includes a web comprised of a panel 800having the same structure as discussed above. Specifically, the panel800 includes a core 802 sandwiched by two layers 804, 806. The materialsfrom which the core and layers may be formed have been described above.However, for the formation of the joist discussed below, the core mayalso comprise a composite wood material. On opposed top and bottom endsof the panel 800 are provided joist ends 808 and 810. As can be seen,the panel 800 and ends 808, 810 combine to form a generally “I” shape inend cross section. As such, the joist described herein may also becommonly referred to as an “I” beam. The joist ends, or support elements808, 810 may in one embodiment be formed of composite lumber, as shownin FIG. 37. In order to accommodate the ends of the panel 800, the joistends 808, 810 would preferably be provided with respective grooves orchannels 812, 814 to receive the end of the panel 800 therein. Thesupport elements may also be formed of wood or other material as wouldbe known to persons skilled in the art. The support elements 808, 810may be of the same or different material.

Alternatively, as shown in FIG. 38, the joist ends 808 a, 810 a may beformed of, for example, and extrusion of metal or composite material. Insuch case, the extrusion may be formed with a groove or channel such asshown at 812 a, 814 a, to receive the ends of the panel 800 therein.

In either of the cases illustrated in FIGS. 37 and 38, the joist ends808, 810, 808 a, 810 a may be secured to the ends of the panel 800 usingvarious forms of adhesive and the like as would be apparent to personsskilled in the art.

As will be understood, the aspects of the invention described herein arebased on the strength of the composite or “sandwich” panels and theunique methods of joining same using modular components. The panelsincorporate a core of foam, such as expanded polystyrene (although othermaterials may equally be used depending on the desired strength of thefoam or other attributes). The foam is sandwiched between cover layers,which are preferably fibre reinforced thermoplastic sheets, in order toform a structural member. These layers may in turn optionally be coveredwith any appropriate material, sheathing, or coating to provide desiredinterior and exterior finishes. In one preferred aspect, the panels arelarge enough to completely form an entire side of the structure withoutany seams or joints. As will be understood, this feature is desirable inorder to minimize thermal losses that normally occur in the case ofseams. Of course, it will be understood, that in the case of largebuildings, some seams would need to be provided.

In accordance with the system of the invention, the panels are joined bya variety of attachment or joint components, or “nodes”, that provideseveral functions. The nodes are preferably made of a composite materialwith high compressive strength and the ability to withstand point loads.Thus, the joint components form mechanical connections between thepanels via either mechanical fasteners and/or adhesives. The jointcomponents also complement the panels in providing structural integrityto the building being constructed. In the latter case, this is theresult of the combination of the high torsion strength of the panels andthe load distribution ability of the joint components.

The system of the invention serves to encapsulate the perimeter ofbuilding (comprised of the panels and nodes), thus providing a method ofattachment while simultaneously distributing all point loads evenlythroughout the panel. In the invention, each panel is preferablydesigned to have sufficient strength so as to maximize absorption ofdeflection loads and to minimize or eliminate potential bending andbuckling loads to which the nodes or joint components may be subjected.In this manner, all point loads are evenly distributed throughout theadjoining panels, thereby resulting in a structure having a highstructural strength.

The system of the invention can be easily and quickly assembled on site.As mentioned above the panels are preferably as large as feasiblypossible and may be manufactured to include one or both interior andexterior finishes, including roofing. This feature also minimizes thetime required assemble the building under construction. As alsomentioned above, the invention also contemplates various kits comprisingany number of components described above. For example, a “simple”structure kit may comprise a plurality of panels, such as the wallpanels, roof panels and floor panels described above, the necessaryconnecting members for such panels and suitable instructions forassembly. Such kits may then be dispatched to any desired location andthe needed structures erected. As will be understood by persons skilledin the art, the systems and kits of the present invention will haveparticular utility in emergency situations where shelters are neededrapidly to protect life and/or property.

In some of the figures included herein, the roof panels is shown asincluding a metal exterior cladding. Such roof panels may preferably be4 feet in width and extend from the ridge joint component to the outerwalls without any other support members being required. In oneembodiment, the upwardly extending seams on the metal cladding meet atthe joints between adjacent roof panels, in which case, a sealing andlocking mechanism may be used to join such panels together.

Although the invention has been described with reference to certainspecific embodiments, various modifications thereof will be apparent tothose skilled in the art without departing from the purpose and scope ofthe invention as outlined in the claims appended hereto. Any examplesprovided herein are included solely for the purpose of illustrating theinvention and are not intended to limit the invention in any way. Anydrawings provided herein are solely for the purpose of illustratingvarious aspects of the invention and are not intended to be drawn toscale or to limit the invention in any way. The disclosures of all priorart recited herein are incorporated herein by reference in theirentirety.

1. A system for constructing a structure comprising: a plurality ofgenerally planar wall panels, each of said wall panels having a laminatestructure comprising a rigid foam core slab sandwiched between first andsecond cover layers, the wall panels defining at least one of wallpanels, roof panels or floor panels; and, a plurality of panelconnecting components for connecting the wall panels to form at leastone of walls, roofs, floors or combinations thereof; the connectingmembers including means for receiving ends of adjacent wall panels. 2.The system of claim 1, wherein the panel connecting components includeat least two slots for receiving and retaining ends of adjacent wallpanels.
 3. The system of claim 1, wherein the connecting componentscomprise elongate, extruded bodies.
 4. The system of claim 1, whereinthe connecting components include corner connecting components, each ofsaid corner connecting components comprising a pair of angularlyseparated slots adapted to receive ends of said wall panels forming acorner of the structure.
 5. The system of claim 1, wherein theconnecting components include first roof panel connecting components,each of said first roof panel connecting components comprising a firstengagement means for engaging an upper end of a wall panel, and a secondengagement means adapted to engage ends of roof panels.
 6. The system ofclaim 1, wherein the connecting components include second roof panelconnecting components, each of said second roof panel connectingcomponents comprising oppositely directed ledges or slots for receivingends of adjacent roof panels for forming a ridge of a roof for thestructure.
 7. The system of claim 1, wherein the connecting componentsinclude sill components, each of said sill components comprising a firstend for resting on a surface and a second end including a firstengagement means for engaging bottom ends of the wall panels.
 8. Thesystem of claim 7, wherein each of said sill components includes asecond engagement means for supporting ends of said floor panels.
 9. Thesystem of claim 5, wherein the first engagement means of each first roofpanel connecting component comprises a bearing surface for resting onthe upper ends of the wall panels or ceiling joints attached to theupper ends of the wall panels.
 10. The system of claim 5, wherein thesecond engagement means of each first roof panel connecting component isangled with respect to the first engagement means for orienting the roofpanel at a desired pitch.
 11. The system according to claim 1, whereinthe first and second cover layers of the wall panels are formed of thesame or different material.
 12. The system of claim 11, wherein at leastone of the first and second cover layers comprises a composite layercomprising a sub foam core covered by sub cover layers.
 13. The systemof claim 11, wherein the outer cover layer of the roof panels comprisesa metal sheet.
 14. The system of claim 1, wherein the panel connectingcomponents comprise pins and corresponding keyholes provided on opposingends of wall panels, the pins being shaped to fit within the keyholes ina locking arrangement to form a connection between adjacent wall panels.15. The system of claim 1, wherein the wall panels include reinforcementmembers at opposed ends for providing at least one of an attachmentmeans or a strengthening means for the panels.
 16. The system of claim15, wherein the panel connecting components are adapted to receive orengage the reinforcement members of adjacent wall panels.
 17. (canceled)18. An I-beam comprising: a pair of support elements separated by a webelement, wherein the web element comprises a laminate structurecomprising a rigid foam core slab sandwiched between first and secondcover layers.
 19. The I-beam of claim 18, wherein the support elementscomprise at least one of composite materials, extruded materials orwood.
 20. The I-beam of claim 19, wherein the support elements includeslots to receive opposing edges of the panel.